公开(公告)号：US20180257299A1

公开(公告)日：2018-09-13

申请号：US15811547

申请日：2017-11-13

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Nag B. Patibandla ,  Ajey M. Joshi ,  Raanan Zehavi ,  Jeffrey L. Franklin ,  Kashif Maqsood

IPC: B29C64/268 ,  B29C64/205 ,  B29C64/245 ,  G02B26/08

Abstract: An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery assembly. The energy delivery assembly includes a light source to emit one or more light beams, a first reflective member having a plurality of reflective facets, and at least one second reflective member. The first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer. The at least one second reflective member is movable such that the at least one second reflective surface is repositionable to receive at least one of the at least one light beam and redirect the at least one of at least one light beam along a two-dimensional path on the uppermost layer.

公开(公告)号：US20180222116A1

公开(公告)日：2018-08-09

申请号：US15942153

申请日：2018-03-30

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B29C64/20 ,  B29C64/386 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/153

CPC classification number: B29C64/153 ,  B22F3/003 ,  B22F3/1055 ,  B22F2003/1056 ,  B29C64/165 ,  B29C64/20 ,  B29C64/205 ,  B29C64/209 ,  B29C64/232 ,  B29C64/236 ,  B29C64/264 ,  B29C64/295 ,  B29C64/307 ,  B29C64/336 ,  B29C64/386 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  Y02P10/295

Abstract: An additive manufacturing system includes a platen, a dispenser apparatus positioned above the platen to dispense a layer of powder over the platen, and an energy source to selectively fuse the layer of powder. The dispenser apparatus includes a support structure, a dispenser secured to the support structure and including a reservoir to hold the powder and one or more openings configured to deliver powder from the reservoir in a linear region that extends along a first axis, a spreader extending along the first axis and secured to the support structure and positioned to spread powder already delivered on the platen by the dispenser, and a drive system to move the support structure along a second axis perpendicular to the first axis such that the dispenser and blade move together to sweep the linear region along the second axis to deposit and level the powder.

公开(公告)号：US11518097B2

公开(公告)日：2022-12-06

申请号：US16694243

申请日：2019-11-25

Applicant: Applied Materials, Inc.

Inventor： Raanan Zehavi ,  Hou T. Ng ,  Nag B. Patibandla ,  Ajey M. Joshi

IPC: B29C64/255 ,  B29C64/209 ,  B29C64/25 ,  B29C64/321 ,  B29C64/245 ,  B33Y40/00 ,  B33Y30/00

Abstract: A dispensing system for an additive manufacturing apparatus includes a frame, a powder reservoir, an agitator and an array of dispensing units positioned below the powder reservoir. The powder reservoir has a first width along a primary axis, and includes a lower portion and an upper portion that is wider than the lower portion along a second axis perpendicular to the primary axis. The agitator is positioned in the upper portion of the powder reservoir. Each dispensing unit includes a nozzle block that has a passage therethrough that defines a nozzle and provides a respective path for the powder to flow from the powder reservoir to the nozzle, and a valve positioned in the passage in the nozzle block to controllably release powder through the nozzle.

公开(公告)号：US20210154930A1

公开(公告)日：2021-05-27

申请号：US16694144

申请日：2019-11-25

Applicant: Applied Materials, Inc.

Inventor： Raanan Zehavi ,  Hou T. Ng ,  Nag B. Patibandla ,  Ajey M. Joshi

IPC: B29C64/209 ,  B29C64/25 ,  B29C64/255 ,  B29C64/329 ,  B29C64/227 ,  B29C64/245 ,  B29C64/264 ,  B29C64/153

Abstract: A dispensing system for an additive manufacturing includes a powder reservoir that contains powder to form an object, and an array of nozzles positioned at a base of the powder reservoir over a top surface of a platen where the object is to be formed. The powder flows from the powder reservoir through the nozzles to the top surface. A respective powder wheel in each nozzle controls a flow rate of the powder. Each wheel has multiple troughs on surface of the wheel. When a motor rotates the wheel, the troughs transport the powder through the nozzle. The rotation speed of the wheel controls the flow rate. For solid parts of the object, the wheel rotates and allows the powder to be deposited on the top surface. For empty parts of the object, the wheel remains stationary to prevent the powder from flowing to the surface.

公开(公告)号：US10717265B2

公开(公告)日：2020-07-21

申请号：US15266494

申请日：2016-09-15

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B29C64/20 ,  B33Y40/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/112 ,  B29C64/386 ,  B29C64/153 ,  B29C64/165

Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a support structure, an actuator coupled to at least one of the platen or the support structure to create relative motion there between along a first axis parallel to the top surface, a plurality of printheads mounted on the support structure, and an energy source. Each printhead includes a dispenser to deliver a plurality of successive layers of feed material over the platen. The printheads are spaced along a second axis perpendicular to the first axis such that during motion along the first axis the plurality of printheads dispense feed material in a plurality of parallel swaths along the first axis. The energy source is configured to fuse at least a portion of the feed material.

公开(公告)号：US20190351667A1

公开(公告)日：2019-11-21

申请号：US16510774

申请日：2019-07-12

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B33Y30/00 ,  B29C64/295 ,  B29C64/20 ,  B22F3/00 ,  B29C64/209 ,  B29C64/236 ,  B22F3/105 ,  B29C64/336 ,  B29C64/264 ,  B29C64/153

Abstract: A module for an additive manufacturing system includes a frame, a dispenser configured to deliver a layer of particles over a platen, an energy source to generate a beam to fuse the particles, and a metrology system having a first sensor to measure a property of the surface of layer before being fused and a second sensor to measure a property of the layer after being fused. The dispenser, first sensor, energy source and second sensor are positioned on the frame in order along a first axis, and the dispenser, first sensor, energy source and second sensor are fixed to the frame such that the frame, dispenser, first sensor, energy source and second sensor can be mounted and dismounted as a single unit from a movable support.

公开(公告)号：US20190308406A1

公开(公告)日：2019-10-10

申请号：US16440731

申请日：2019-06-13

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B33Y30/00 ,  B29C31/02 ,  B05C19/04 ,  B22F3/00 ,  B29C64/205 ,  B29C64/153 ,  B29C64/321 ,  B29C64/241 ,  B22F3/105 ,  B29C64/20

Abstract: An additive manufacturing apparatus includes a dispensing system positionable over a platen to deliver a powder, an actuator to move the dispensing system along a scan axis, and an energy source to fuse a portion of the powder. The dispensing system has a hopper to hold the powder and a dispenser. The dispenser includes a channel extending along a longitudinal axis from a proximal end to a distal end. The proximal end of the channel of the dispenser is configured to receive the powder from the powder source. A powder conveyor is positioned within the channel to move the powder from the proximal end along a length of the channel, and a plurality of apertures are arranged along the longitudinal axis of the channel. The dispenser is configured such that flow of powder through each aperture is independently controllable.

公开(公告)号：US10350824B2

公开(公告)日：2019-07-16

申请号：US15265631

申请日：2016-09-14

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B29C67/00 ,  B29C64/153 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/386 ,  B29C64/20 ,  B29C64/336 ,  B29C64/264 ,  B29C64/205 ,  B29C64/165 ,  B29C64/295 ,  B29C64/209 ,  B29C64/307 ,  B22F3/105 ,  B33Y10/00 ,  B22F3/00 ,  B33Y70/00

Abstract: An additive manufacturing system includes a platen having a top surface to support an object being manufactured, a support that is movable along a vertical axis, an actuator to move the support along the vertical axis, a dispenser to deliver a plurality of successive layers of feed material over the platen, an energy source configured to fuse at least a portion of the feed material, and a controller. The dispenser and energy source are mounted on the support over the platen such that motion of the support along the vertical axis moves the dispenser and energy source together toward or away from the top surface of the platen. The controller is coupled to the actuator, dispenser and energy source and configured to cause the actuator to move the support to lift the dispenser and actuator away from the top surface after each of the plurality of successive layers is delivered.

公开(公告)号：US20180222114A1

公开(公告)日：2018-08-09

申请号：US15942116

申请日：2018-03-30

Applicant: Applied Materials, Inc.

Inventor： Hou T. Ng ,  Raanan Zehavi ,  Nag B. Patibandla

IPC: B29C64/153 ,  B29C64/386 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: B29C64/153 ,  B22F3/003 ,  B22F3/1055 ,  B22F2003/1056 ,  B29C64/165 ,  B29C64/20 ,  B29C64/205 ,  B29C64/209 ,  B29C64/232 ,  B29C64/236 ,  B29C64/264 ,  B29C64/295 ,  B29C64/307 ,  B29C64/336 ,  B29C64/386 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  Y02P10/295

Abstract: An additive manufacturing system includes a platen to support an object being manufactured, a dispenser to deliver a plurality of successive layers of a powder over the platen, and energy source configured to fuse at least a portion of the powder. The dispenser is configured to deliver the powder in a linear region that extends along a first axis. The dispenser and actuator are supported by a support structure, and the actuator is coupled to the support structure to move the support structure along a second axis perpendicular to the first axis such that the dispenser and energy source move as a single unit with the support structure and the linear region sweeps along the second axis to deposit the powder along a swath over the platen to form a layer of powder.

公开(公告)号：US11524455B2

公开(公告)日：2022-12-13

申请号：US16694144

申请日：2019-11-25

Applicant: Applied Materials, Inc.

Inventor： Raanan Zehavi ,  Hou T. Ng ,  Nag B. Patibandla ,  Ajey M. Joshi

IPC: B29C64/255 ,  B29C64/209 ,  B29C64/25 ,  B29C64/329 ,  B29C64/227 ,  B29C64/264 ,  B29C64/153 ,  B29C64/245 ,  B33Y40/00 ,  B33Y10/00 ,  B33Y30/00

Abstract: A dispensing system for an additive manufacturing includes a powder reservoir that contains powder to form an object, and an array of nozzles positioned at a base of the powder reservoir over a top surface of a platen where the object is to be formed. The powder flows from the powder reservoir through the nozzles to the top surface. A respective powder wheel in each nozzle controls a flow rate of the powder. Each wheel has multiple troughs on surface of the wheel. When a motor rotates the wheel, the troughs transport the powder through the nozzle. The rotation speed of the wheel controls the flow rate. For solid parts of the object, the wheel rotates and allows the powder to be deposited on the top surface. For empty parts of the object, the wheel remains stationary to prevent the powder from flowing to the surface.